Camshaft, Removing And Installing: Installing: Notes

• The sealing surfaces must be free of oil and grease.
• Pay attention that all roller rocker levers rest on the valve stem ends.

-- Remove any sealant residue from the groove on the cylinder head cover as well as on sealing surfaces. They must be free of oil and grease.

In the case that the crankshaft has been turned in the meantime:

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-- Turn the crankshaft on the hex fitting -2- to "TDC" point.

• In "TDC" point the flattened position -1- is in an imaginary vertical line between the camshaft sprockets.

-- Then turn the crankshaft 90° counter-clockwise out of "TDC".

-- Bring the pin of the cam adjustment actuator into the installation position. Refer to Installing - The cam adjustment actuator pin must be brought into the installation position. .

-- Lubricate the running surfaces of both camshafts.

-- Place the intake camshaft -A- in the cylinder head. Turn the cam lobes of cylinder 4 -arrows- upward.

Fig 1: Identifying Intake Camshaft And Cylinder Head

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-- Place the exhaust camshaft in the cylinder head cover as shown. The cam pair -A and B- must be pushed together in direction of -arrows-.

Fig 2: Placing Exhaust Camshaft In Cylinder Head Cover

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-- Turn the exhaust camshaft until the markings -A and B- align.

Fig 3: Locating Alignment Marks

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-- Apply the sealant on the clean sealing surface of the cylinder head cover as shown -arrows-.

Fig 4: Sealant Application Locations

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• Sealant bead thickness: 1.5 to 2.5 mm (0.059 to 0.098 inches)

-- Secure the camshaft and place the cylinder head cover with the camshaft on the cylinder head.

-- Lightly push on the cylinder head cover by hand and while doing so turn the camshaft slightly in direction of -arrows- until the cylinder head cover lays >>free of tension<< on the cylinder head.

Fig 5: Turning Camshafts

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-- Replace the cylinder head cover bolt after removing.

-- Tighten the bolts in several steps. Refer to Figure for the tightening sequence.

• Pay attention that the cylinder head cover is not tilted.

With Marks in the Cylinder Head Cover 

Fig 6: Identifying Intake Camshaft With Adapter T40266

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-- Turn the intake camshaft with the : T40266  in direction of -arrow A- until the marks -1 and 2- align. Push the : T40271/2  in the chain sprocket splines in direction of -arrow B-.

-- Turn the exhaust camshaft with the : T40266  in direction of -arrow A- until the marks -1 and 2- align. Push the : T40271/1  in the chain sprocket splines in direction of -arrow B-. The mark -2- is offset slightly to the right.

Fig 7: Turning Exhaust Camshaft W/ T40266

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Without Marks in the Cylinder Head Cover 

Fig 8: Identifying Markings And Camshaft Clamp T40271/2

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-- Turn the intake camshaft in direction of -arrow 1- until the marking -3- aligns with the : T40271/2  .

-- Slide the : T40271/2  into the chain sprocket splines in direction of -arrow 2-.

-- Turn the exhaust camshaft in direction of -arrow 1- until the marking -3- aligns with the : T40271/1  .

Fig 9: Identifying Markings And Camshaft Locating Tool T40271/1

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-- Slide the : T40271/1  into the chain sprocket splines in direction of -arrow 2-.

Continued for All Engines: 

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-- Turn the crankshaft on the hex fitting -2- to the "TDC point". The flat area -1- faces upward toward the cylinder head when in the "TDC point".

• In "TDC" point the flattened position -1- is in an imaginary vertical line between the camshaft sprockets.